Centralized management system for maintenance parts

ABSTRACT

A centralized management system for managing maintenance parts of machines at multiple plants includes: a warehouse facility for providing a concentrated storage of the maintenance parts for multiple types of the machines at multiple plants; a necessary parts management device for managing whether the maintenance parts are required for the machine; and a parts shipment management device for determining the maintenance parts to be shipped from the warehouse facility based on management information in the necessary parts management device. The present invention provides a system for managing maintenance parts that allows management costs to be restricted while allowing changes in the status of machines at plants to be handled in a flexible manner.

FIELD OF INVENTION

[0001] The present invention relates to a system for managingmaintenance parts for multiple types of machines located in multipleplants.

BACKGROUND OF THE INVENTION

[0002] Conventionally, a system for managing maintenance parts formultiple types of machines located in a plant has involved storingneeded maintenance parts in the plant. When a maintenance part needs tobe replaced due to a maintenance inspection of a machine or the like,the stored maintenance part is used for the machine, and an order isissued to replace the stored maintenance part that was used.

[0003] Thus, for an enterprise that operates multiple plants,maintenance parts are stored and managed independently within eachplant, and maintenance parts are generally stocked so that there are noshortages in any of the plants.

[0004] Thus, the conventional organizational method may lead toshortages in maintenance parts and may lead to work delays in cases suchas when there is a sudden increase in the number of maintenance partsneeded as a consequence of a sudden rise in production volume. On theother hand, stocking large quantities of maintenance parts to be able tohandle these types of changes in the environment increases maintenancecosts. Furthermore, if more than one type of maintenance part is used inthe plant, the maintenance costs are even greater.

OBJECT AND SUMMARY OF THE INVENTION

[0005] The object of the present invention is to overcome these problemsand to be able to flexibly respond to changes in the status of machineslocated in different plants while keeping maintenance costs down.

[0006] The present invention provides a centralized maintenance partsmanagement system that includes: a warehouse facility for storing, in acentralized manner, a maintenance part for a plurality of types ofmachines located at a plurality of plants; a necessary parts managementdevice for managing whether the maintenance part is necessary or not forthe machines; and a parts shipment management device for specifying amaintenance part to be shipped from the warehouse facility based onmanagement information in the necessary parts management device.

[0007] More specifically, the maintenance parts for the multiple typesof machines needed in the multiple plants are managed in a centralizedmanner in the warehouse facility. The maintenance parts are suppliedbased on information about an operation status of the machines in theplants or based on maintenance part supply requests. Thus, even if thetotal quantity of the maintenance parts stocked in the warehousefacility is kept at an appropriate level for the plants that thewarehouse facility supplies, a change in the machines in one of theplurality of plants, e.g., a sudden increase in the number ofmaintenance parts needed, can be handled in a flexible manner becausethe total quantity of the stocked maintenance parts is high.

[0008] By managing the maintenance parts for the multiple types ofmachines in the multiple plants with the warehouse facility, it ispossible to restrict the quantities of the stocked maintenance parts toan appropriate level while also keeping management costs down. Also,changes in the status of the machines in the plants can be handled in aflexible manner.

[0009] According to an embodiment of the present invention, there isalso included an ordering management device for determining amaintenance part to be ordered and a quantity thereof based on inventoryinformation of the maintenance part to be ordered in the warehousefacility or based on management information in the necessary partsmanagement device.

[0010] Thus, the maintenance parts to be newly ordered and the quantitythereof can be determined automatically based on inventory informationof the maintenance part to be ordered in the warehouse facility and/orinformation relating to whether the maintenance part to be ordered isneeded for the machines in the plant being supplied. This makes themanagement of maintenance parts easier.

[0011] According to another embodiment of the present invention, theordering management device is set up to allow input of a target valuefor a total price of the maintenance parts stored in the warehousefacility and, when determining a quantity of maintenance parts to beordered, the quantity of maintenance parts to be ordered is reducedaccording to set conditions so that a total price of the maintenanceparts stored in the warehouse facility approaches the target value.

[0012] There are many cases where maintenance part management costs arereduced by setting a target total price of the maintenance parts beingstored.

[0013] In such cases, an order volume of the maintenance parts can beautomatically controlled to approach this target value, thereby makingmaintenance part management easier.

[0014] According to another embodiment of the present invention, theordering management device estimates a quantity of the maintenance partsthat will be needed based on changes in quantities of the maintenanceparts shipped out from the warehouse facility, changes in maintenanceinspections of the machines, or changes in operating status of themachines and determines a maintenance part to be ordered and a quantitythereof.

[0015] Thus, when periodic inspections are simply repeated at fixedintervals, maintenance part management can involve simply orderingmaintenance parts to compensate for the maintenance parts shipped out inresponse to the periodic inspection. However, there are many cases wherethe quantities of maintenance parts needed by the plants being suppliedvary, e.g., due to changes in usage frequency of the machines.

[0016] In such cases, the quantity of maintenance parts that will beneeded is estimated based on changes in quantities of the maintenanceparts shipped out from the warehouse facility, changes in maintenanceinspections of the machines, or changes in operating status of themachines, and the maintenance parts to be ordered and the quantitiesthereof are determined based on these changes, thereby allowing thesystem to respond appropriately to changes in the status of the machinesat the plants.

[0017] According to another embodiment of the present invention, thereis included an inspection period management device for storinginformation relating to periodic inspection periods for the machinesand, when there is a new machine to be managed in one of the plants, theinspection period management device uses information relating toperiodic inspection of existing machines to determine a periodicinspection period for the machine to be newly managed that is offsetfrom the periodic inspection periods of existing machines.

[0018] When machines in a supplied plant are periodically inspected andthe periodic inspection period is carried out in a concentrated mannerover a short period of time, the shipping of maintenance parts neededfor the periodic inspections from the warehouse facility becomesconcentrated as well. Thus, a quick and efficient supply of maintenanceparts can be difficult.

[0019] Therefore, information regarding the periodic inspection periodsfor the machines is managed in a centralized manner at the warehousefacility. If there is a new machine to be managed, the periodicinspection period for the new machine is set up so that the periodicinspection period for the new machine is offset from the periodicinspection periods for the existing machines. This inspection period forthe new machine can then, for example, be recommended to the plant. Thismakes it possible to set up an environment where maintenance parts canbe supplied in a quick and efficient manner.

[0020] According to another embodiment of the present invention, thenecessary parts management device is set up to store and maintainplant-by-plant inventory information indicating quantities of themaintenance parts stored in the plurality of plants and uses theplant-by-plant inventory information in evaluating whether themaintenance part is necessary or not.

[0021] More specifically, some of the maintenance parts for the machinesin the plants must be replaced quickly when the maintenance parts areneeded. Even with centralized management at the warehouse facility ofthe maintenance parts, the types of maintenance parts that are neededimmediately are usually not stocked at the individual plants.

[0022] When the warehouse facility is aware of the maintenance partsstocked at each plant, and when this awareness is reflected in themanagement of shipments of maintenance parts from the warehousefacility, it is possible to provide more appropriate maintenance partmanagement.

[0023] According to another embodiment of the present invention, when asingle machine needs a plurality of maintenance parts during amaintenance inspection, the parts shipment management device is set upto determine the maintenance parts to be shipped out successively as themaintenance inspection progresses.

[0024] If the machines in the plants are machines that require longperiods of time for maintenance inspections, e.g., aircraft transportedto a maintenance plant, sending necessary maintenance parts to plants inbatches will result in plants accumulating maintenance parts that arenot immediately needed.

[0025] By having the warehouse facility send maintenance parts to aplant successively as the maintenance inspection proceeds, excessiveaccumulation of maintenance parts at the plant can be prevented.

[0026] According to another embodiment of the present invention, thewarehouse facility is an automated warehouse.

[0027] By storing the maintenance parts for the multiple types ofmachines at the multiple plants in an automated warehouse and providingcentralized management, the necessary maintenance parts can beappropriately and quickly sent to the plants.

[0028] The automated warehouse referred to here is a warehouse facilityequipped with a product storage section storing a product (e.g.,maintenance parts in the present invention), a packaging section for theautomated warehouse to receive and ship products, and a transportingdevice for automatically transporting the products between the twosections.

[0029] The above, and other objects, features and advantages of thepresent invention will become apparent from the following descriptionread in conjunction with the accompanying drawings, in which likereference numerals designate the same elements.

BRIEF DESCRIPTION OF THE FIGURES

[0030]FIG. 1 is a drawing showing the overall architecture of a systemaccording to an embodiment of the present invention;

[0031]FIG. 2 is a side view of an automated warehouse according to anembodiment of the present invention;

[0032]FIG. 3 is a front view of an automated warehouse according to anembodiment of the present invention;

[0033]FIG. 4 is a plan view of an automated warehouse according to anembodiment of the present invention;

[0034]FIG. 5 is a flowchart of the maintenance part management operationaccording to an embodiment of the present invention;

[0035]FIG. 6 is a flowchart of the operating status registeringoperation according to an embodiment of the present invention;

[0036]FIG. 7 is a flowchart of the split shipment operation according toan embodiment of the present invention; and

[0037]FIG. 8 is a flowchart of the new registration operation accordingto an embodiment of the present invention.

LIST OF DESIGNATORS

[0038] MC: machine

[0039] MP: maintenance part

[0040] MT: inspection period management device

[0041] OC: order management device

[0042] PM: necessary parts management device

[0043] PR: parts shipment management device

[0044] SS: warehouse facility

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0045] The embodiments of a centralized maintenance management systemaccording to the present invention will be described using the figures.

[0046] Overall Structure

[0047] A centralized maintenance part management system MM is a systemfor providing centralized management of maintenance parts for multipletypes of machines in multiple plants. In the example used in theembodiment shown in FIG. 1, multiple types of devices 51, e.g., deviceA, device B, device C, device A′, device B′, device C′, located in thetwo plants, plant X and plant Y, serve as the machines MC for whichmaintenance is to be performed. The devices 51 in plant X and plant Yare primarily manufacturing devices, but they also include testingdevices and the like. The maintenance parts for the devices includemaintenance parts shared by multiple types of devices 51 and maintenanceparts that are specifically for particular devices.

[0048] A large portion of the replacement maintenance parts for thedevices 51 are stored in a centralized manner in a maintenance partmanagement warehouse MS. A warehouse facility SS set up at themaintenance parts management warehouse MS and a management servercomputer 40 managing shipping and receiving for the warehouse facilitySS form the key elements of a maintenance parts centralized managementsystem MM. In the example of this embodiment shown in FIG. 1, thewarehouse facility SS is a so-called automated warehouse, and thewarehouse facility SS will be referred to in the description below asthe “automated warehouse SS”.

[0049] Each plant stores maintenance parts, and waiting for shipment ofthe maintenance parts from the maintenance parts management warehouse MShas a major impact on the operation of the devices 51. The managementserver computer 40 stores inventory information, which is organized byplant, indicating quantities of maintenance parts stored in each plant.The quantities of maintenance parts stored in each plant are kept assmall as possible in order to reduce maintenance costs and the like.Rather than having the number of stored maintenance parts beproportional to the number of the devices 51 that use the maintenancepart, the number of stored maintenance parts for devices 51 isproportionally smaller when there are more devices 51.

[0050] Structure of the Automated Warehouse SS

[0051] The automated warehouse SS of this embodiment stores varioustypes of maintenance parts MP mounted on pallets. The plan drawing inFIG. 4 shows: storage shelves 1; a packaging section LT handling themaintenance parts MP that are received by or sent out from the storageshelf 1; and a stocker crane 2 serving as a transporting device thatautomatically transports objects between the packaging section LT andparts storage sections 10 of the storage shelves 1.

[0052] The storage shelves 1 are arranged on either side of a movementpath of the stacker crane 2, as shown in FIG. 2 and FIG. 3. On eachstorage shelf 1, the parts storage sections 10 are arranged, verticallyand horizontally, and the parts storage sections 10 can hold twomaintenance parts MP along the depth axis. Each of the parts storagesections 10 is formed by a pair of wooden arms 10 a, which supports frombelow at the left and right a pallet, on which the maintenance part MPis mounted. The wooden arms 10 a are attached to struts 10 b via supportmembers.

[0053] The packaging section LT includes: a shipping and receivingconveyor 30 for the maintenance parts MP which are to be shipped fromand received by the automated warehouse SS; and a receiving conveyor 11and a shipping conveyor 12 which branch off so that the conveyancedirections of the receiving conveyor 11 and the shipping conveyor 12 areperpendicular to the shipping and receiving conveyor 30.

[0054] Both the receiving conveyor 11 and the shipping conveyor 12 arearranged in two rows so that the maintenance parts MP can be conveyedalong the two rows. The intervals between the two rows are the same asthe interval between maintenance part storage positions.

[0055] A lifter 14 is disposed at each conveyance row at the end of thereceiving conveyor 11 toward the storage shelves 1. The lifter 14 liftsthe maintenance part MP to move the maintenance part MP between thepackaging section LT and a mounting device 3 of the stacker crane 2.Similarly a lifter 15 is disposed for each conveyance row of theshipping conveyor 12.

[0056] Elevator conveyors 31 are disposed at the connecting point of thereceiving conveyor 11 and the shipping conveyor 12 with the shipping andreceiving conveyor 30.

[0057] The stocker crane 2 includes a truck 2 a running along a guiderail 20 a on a floor side; a pair of struts 2 b projected from the truck2 a; and a platform 2 c that is vertically guided for raising andlowering by the struts 2 b. The pair of struts 2 b are connected attheir upper ends, and the connecting section is guided by a guide rail20 b on a ceiling side.

[0058] The platform 2 c includes a slide-fork type mounting device 3that mounts the maintenance part MP between the parts storage sections10. Two maintenance parts MP can be mounted along the mounting directiononto the mounting device 3. The stroke of the mounting device 3 is setup with a displacement adequate for positioning two maintenance parts MPto two maintenance part storage positions of the maintenance partstorage sections 10.

[0059] Operations Performed by the Management Server Computer 40

[0060] The management server computer 40 is installed with a databaseserver program and includes: a maintenance database, which monitors theoperations of the devices 51 in the different plants and manages thesupply of maintenance parts MP to the different plants; and a partsprocurement database for ordering the maintenance parts MP from partssuppliers.

[0061] A device management computer 41, installed in each plant toaccess the management server computer 40, performs operations such asthe collecting of data relating to an operation status of the devices 51that are connected to a network.

[0062] The operations of the management server computer 40 will bedescribed using the flowcharts in FIG. 5 through FIG. 8, which show thesteps performed by the management server computer 40.

[0063] The management server computer 40 executes the maintenance partmanagement operation shown in FIG. 5 in response to a receive datarequest from Plant X or Plant Y or from a purchasing department computer42 that handles the issuing of orders for the maintenance part MP.

[0064] If the receive data request is from the device managementcomputer 41 of a plant, the data sent from the device managementcomputer 41 of the plant is received, and the received data is checkedto see if it is: data relating to the operation status of the devices 51installed in the plant (step S1); registration data for a newlyinstalled device 51 (step S3); or data relating to inspection progressstatus if the devices 51 are being inspected over a long period of timein the plant (step S5). If so, an operation status registrationoperation (step S2), a new registration operation (step S4), or a splitshipment operation (step S6) is executed, respectively.

[0065] If data is received requesting operations to be performed by thecomputer 42 of the purchasing department to issue an order to the partssupplier for the maintenance part MP (step S7), an ordering operation isexecuted (step S8).

[0066] The reporting of the operation status of the devices 51 (step S1)can be performed, for example, by the device management computer 41 inthe plant periodically, e.g., once a day. The operation status dataprimarily includes operating time data for each of the devices 51. Alongwith the operating status report, information about changes in thenumber of maintenance parts MP stored in each plant is sent.

[0067] The operation status registration operation (step S2) executedwhen the operation status is reported is shown in the flowchart in FIG.6. First, the received operation status data for the devices 51 areregistered in a maintenance database (step S1 ). This maintenancedatabase also stores the quantities of the maintenance part MP stored atthe plant. When changes in the quantities of the maintenance part MPstored at each plant are reported along with the operation statusreport, this information is used to update the data stored in themaintenance database.

[0068] Next, an evaluation is made as to whether a shipment from theautomated warehouse SS is needed to replace the maintenance part MP fora device 51 based on whether or not the accumulated operation time ofthe device 51 has reached a set time for parts replacement (step S12).If the maintenance part MP needs to be shipped from the automatedwarehouse SS for one of the devices 51, a further evaluation is made asto whether the plant is stocked with the necessary quantity of that typeof maintenance part MP, based on the inventory-by-plant information forthe maintenance part MP stored in the maintenance database (step S13).If the maintenance part MP is not in the plant's inventory or if thequantity is insufficient, an instruction is issued to a controller ofthe automated warehouse SS to ship the necessary quantity of themaintenance part MP, and the shipment quantity and the shipment data areregistered in the maintenance database (step S14).

[0069] With this instruction, the automated warehouse SS activates thestacker crane 2, the shipping conveyer 12, and the like and ships themaintenance part MP to the corresponding plant using shipping means suchas a truck.

[0070] Thus, the maintenance server computer 40 functions as a necessaryparts management device PM for managing information about whether themaintenance part MP is needed for the machine MC and also forfunctioning as a parts shipment management device PR that specifies themaintenance parts MP to be shipped from the automated warehouse SS basedon management information of the necessary parts management device PM.

[0071] The inventory of the maintenance part MP in the automatedwarehouse SS declines due to the shipment of the maintenance part MP. Tocompensate for this reduction, the maintenance part MP that should beordered and the quantity to order are registered in the partsprocurement database (step S20).

[0072] With regard to the ordering of the maintenance part MP, themanagement server computer 40 can be set to a necessary quantityestimating mode, in which the quantity of the maintenance part MP israised or lowered by estimating the future quantity of the maintenancepart MP that is needed when ordering. The management server computer 40can also be set to a total price restricting mode, in which the totalprice of the maintenance part MP stored in the automated warehouse SS islimited to a target price.

[0073] If the necessary quantity estimating mode is active (step S15),the necessary quantity of the maintenance part MP is predicted bycarrying out an approximation function on the change in inventoryquantity over a fixed period in the maintenance database for themaintenance part MP. The order quantity is increased or reduced based onthis prediction value (step S16).

[0074] When the total price restriction mode described above is activeand the target total price has been entered using a keyboard or the likeof the management server computer 40 (step S17), the order quantity forthe maintenance part MP is reduced based on condition settings so thatthe total price of the maintenance part MP stored in the automatedwarehouse SS approaches the target value (step S18). The conditionsettings for this reduction of the order quantity for the maintenancepart MP can be determined by a reduction method such as by setting aminimum necessary quantity for each maintenance part MP, with the orderquantity of the maintenance parts MP being set to “0” if the quantity ofthe maintenance part MP in the inventory exceeds the minimum necessaryquantity. Alternatively, priorities can be assigned to the differentmaintenance parts MP, with order quantity reductions being increased formaintenance parts MP having low priorities.

[0075] With the operation in step S18, if the quantity of themaintenance part MP to be ordered is greater than “0” (step S19), theorder quantity is registered in the parts procurement database (stepS20).

[0076] Based on the data registered in the parts procurement databaseaccumulated in this manner, when the management server computer 40receives from the purchasing department computer 42 data indicating arequest for performing processing to issue an order to the supplier ofthe maintenance part MP (step S7 in FIG. 5), the maintenance part MPthat needs to be ordered and the quantity thereof are output as a listto the purchasing department computer 42. Thus, an order issuingoperation is executed (step S8 in FIG. 5). In the purchasing division,the order data for the maintenance part MP is sent to a computer 43 ofthe associated parts supplier, and the order is placed for themaintenance part MP.

[0077] When an order for the maintenance part is issued and themaintenance part MP that is shipped by the parts supplier is received atthe automated warehouse SS, information regarding these actions isregistered in the parts procurement database, and the maintenance partinventory quantity in the maintenance database is updated.

[0078] Thus, the management server computer 40 functions as an ordermanagement device OC that determines the maintenance part MP and thequantity to be ordered based on the management information in thenecessary parts management device PM.

[0079] Next, the new registration operation (step S4) mentioned abovewill be described.

[0080] The new registration operation in step S4 of FIG. 5 is shown inthe flowchart in FIG. 7. First, the new registration data received fromthe device management computer 41 at the plant is registered in themaintenance database (step S21).

[0081] The new registration data normally includes a list of maintenanceparts MP needed by the newly installed device 51 and operating time dataat which each maintenance part MP should be replaced. The newregistration data also includes information about periodic inspectionintervals, if periodic inspections of the device 51 are needed. Otherinformation may be included in the new registration data, such asinformation indicating the start of maintenance inspection operations,if maintenance inspection for the device 51 requires a long interval,and data indicating the relationship between the maintenance parts MPand the progress level of the maintenance inspection operation.

[0082] If the new registration data includes data indicating the needfor periodic inspection data for the device 51 and the interval for theperiodical inspections (step S22), a search is performed on the periodicinspection period information for the devices 51 that are registered inthe maintenance database as requiring periodic inspections. Arecommended periodic inspection period that is offset from the periodicinspection periods that have already been registered is output to thedevice management computer 41 (step S23).

[0083] Then, on the plant side, an assessment is made as to whether theperiodic inspection period posted from the management server computer 40is possible or not, and a period as close to the recommended periodicinspection period is registered in the maintenance database of themanagement server computer 40.

[0084] Thus, the management server computer 40 functions as aninspection period management device MT that manages the periodicinspection periods of the devices 51 that need periodic inspections andthat are located in the different plants.

[0085] Next, the split shipment operation (step S6) will be described.The split shipment operation is performed if the data received from theplant's device management computer 41 is related to a progress status ofan inspection when a device 51 is being inspected over a long period oftime in a plant (step S5).

[0086] The operations performed in this split shipment operation areshown in the flowchart in FIG. 8. The maintenance database is checked tosee that it has registered data relating to the maintenance inspectionfor which a progress status report has been received (step S31). Usingdata in the maintenance database about the relationship between progresslevels of the maintenance inspection and maintenance parts MP thatbecome necessary (the data registered in the new registrationoperation), an evaluation is made as to whether the received maintenanceinspection progress level is a progress level for which the maintenancepart MP should be shipped (step S32). If a progress level for which themaintenance part MP should be shipped has been reached, the controllerof the automated warehouse SS is instructed to ship the correspondingmaintenance part MP (step S33).

[0087] Alternative Embodiment

[0088] Alternative embodiments of the present invention will bedescribed.

[0089] (1) In the embodiment described above, the functions of thenecessary parts management device PM, the parts shipment managementdevice PR, an order management device OC, and the inspection periodmanagement device MT are all part of the management server computer 40.However, each of the functions of these devices can be provided byseparate computers. Alternatively, the management server computer 40 canbe formed from multiple computers by clustering.

[0090] (2) In the embodiment described above, the automated warehouse isa three-dimensional automated warehouse in which the parts storagesections 10 are arranged in vertical and horizontal rows. However, itwould also be possible to use various other types of automatedwarehouses instead, e.g., warehouses where items are laid out in a flatarrangement.

[0091] Furthermore, the present invention can also be used in caseswhere the warehouse facility SS is not an automated warehouse but is awarehouse with standard shelves, e.g., fixed shelves, or a warehousewhere items are laid out flat.

[0092] (3) In the embodiment described above, when determining themaintenance part to be ordered by the order management device OC and thequantity thereof, this information is determined based on the shipmentinformation of the parts shipment management device PR. However, itwould also be possible to determine the maintenance part to be orderedand the quantity thereof independent from the shipping operation of themaintenance part and based instead on inventory information (inventoryquantity) of the maintenance part MP in the automated warehouse SS.

[0093] (4) In the embodiment described above, when the quantity ofmaintenance parts MP needed for the future is to be estimated, theestimate is made based on changes in the quantity of the maintenancepart MP shipped from the automated warehouse SS. However, it would alsobe possible to have information about maintenance inspections conductedon machines entered at the plant so that the quantity of the maintenanceparts MP that will be needed in the future can be estimated from thechanges in the number of maintenance inspections conducted over a fixedperiod. Alternatively, the quantity of the maintenance parts MP thatwill be needed in the future can be estimated independent from theshipping operations for the maintenance part by using the changes in theoperation status of the devices 51 (changes in the device operationrates).

[0094] (5) In the embodiment described above, production devices and thelike are multiple types of machines in the plants. However, the presentinvention can be used when the machines are aircraft or automobiles andthe plants are maintenance plants.

[0095] (6) In the embodiment described above, the order managementdevice OC outputs data for ordering the maintenance part MP as a list,and based on this list, the purchasing department orders the maintenancepart MP. However, the order management device OC can be set up todirectly issue orders to the computer 43 of the parts supplier.

[0096] With another embodiment of the present invention, maintenanceparts for multiple types of machines at multiple plants are stored in acentralized manner in a warehouse facility. This allows the stock ofmaintenance parts to be limited to an appropriate quantity, allowsmanagement costs to be kept down, and allows flexible responses tochanges in the status of machines at the plants.

[0097] With an embodiment of the present invention, at least one of theinventory information for the maintenance part in the warehouse facilityand information about whether or not the maintenance part is required ina machine at a plant supplied by the warehouse is used to automaticallydetermine the maintenance part to be newly ordered and the quantitythereof. This simplifies the management of the maintenance parts.

[0098] A target value for the total price of maintenance parts beingstored is often used as a way to reduce management costs for themaintenance parts. With another embodiment of the present invention, theorder volume for the maintenance parts is automatically controlled sothat the target value is approached. This simplifies management ofmaintenance parts.

[0099] To manage the maintenance parts, the quantity of the maintenanceparts needed by the plants often changes due to reasons such as a changein a usage frequency of the machines. With another embodiment of thepresent invention, the maintenance parts to be ordered and the quantitythereof are determined by estimating the number of maintenance partsthat will be needed based on changes in the number of maintenance partsshipped from the warehouse facility, changes in the number ofinspections of the machines, or changes in the operating status of themachines. As a result, appropriate responses can be made to changes inthe operating status of machines in the plants being supplied.

[0100] When the machines in the supplied plants are inspectedperiodically and the periodic inspections periods are concentrated in ashort period of time, the shipping operations from the warehousefacility for maintenance parts needed for the periodic inspectionsbecomes concentrated, thereby a quick and reliable supply of themaintenance parts difficult. With another embodiment of the presentinvention, the warehouse facility provides centralized management ofinformation regarding periodic inspection periods for the machines. Whena new machine is to be managed, a period is determined for periodicinspections for the new machine that is offset from the periodicinspection periods of the other machines, and this determined period isrecommended to the plant. This provides an environment where themaintenance parts can be supplied quickly and efficiently.

[0101] Among the maintenance parts for the machines at the plants, thereare ones that need to be replaced quickly when they are needed. Even ifmaintenance parts are managed in a centralized manner by a warehousefacility, individual plants often do not have these emergencymaintenance parts in stock. With another embodiment of the presentinvention, the warehouse facility keeps track of the maintenance partsstocked at each plant and this information is reflected in the handlingof shipping of the maintenance parts from the warehouse facility.

[0102] If the machines in the plants require long maintenance inspectionperiods, as in aircraft transported to a maintenance plant, sending thenecessary maintenance parts in batches leads to the accumulation ofmaintenance parts that will not be needed immediately. With anotherembodiment of the present invention, the supplying of maintenance partsfrom the warehouse facility to the plant is performed successively asthe maintenance inspection proceeds at the plant. This preventsexcessive accumulation of maintenance parts at the plant.

[0103] According to another embodiment of the present invention, themaintenance parts for multiple types of machines at multiple plants arestored in an automated warehouse and managed in a centralized manner.This allows necessary maintenance parts to be supplied to the plantsquickly and reliably.

What is claimed is:
 1. A centralized maintenance parts management systemcomprising: a warehouse facility for storing, in a centralized manner, amaintenance part for a plurality of types of machines located at aplurality of plants; a necessary parts management device for managinginformation about whether said maintenance part is necessary for saidmachines; and a parts shipment management device for specifying amaintenance part to be shipped from said warehouse facility based onsaid management information in said necessary parts management device.2. The centralized maintenance part management system as described inclaim 1, further comprising an order management device for determining amaintenance part to be ordered and a quantity thereof based on inventoryinformation of said maintenance part to be ordered in said warehousefacility or based on said management information in said necessary partsmanagement device.
 3. The centralized maintenance part management systemas described in claim 2, wherein: said order management device allowsinput of a target value for a total price of said maintenance partstored in said warehouse facility; and when determining said quantity ofsaid maintenance part to be ordered, said quantity of said maintenancepart to be ordered is reduced according to set conditions so that saidtotal price of said maintenance part stored in said warehouse facilityapproaches said target value.
 4. The centralized maintenance partmanagement system as described in claim 2, wherein: said ordermanagement device estimates a quantity of a maintenance part neededbased on at least one of a change in a quantity of said maintenance partto be shipped from said warehouse facility, a change in a maintenanceinspection of said machines, and a change in an operating status of saidmachines; and said order management device determines said maintenancepart to be ordered and said quantity thereof.
 5. The centralizedmaintenance part management system as described in claim 1, furthercomprising an inspection period management device for storinginformation relating to periodic inspection periods for said machines,wherein when there is a new machine to be managed in one of said plants,said inspection period management device uses said information relatingto said periodic inspection periods for said machines to determine aperiodic inspection period for said machine to be newly managed that isoffset from said periodic inspection periods of said machines.
 6. Thecentralized maintenance part management system as described in claim 1,wherein said necessary parts management device stores and maintainsplant-by-plant inventory information indicating a quantity of saidmaintenance part stored in said plurality of plants and uses saidplant-by-plant inventory information to evaluate whether saidmaintenance part is necessary.
 7. The centralized maintenance partmanagement system as described in claim 1, wherein, said parts shipmentmanagement device determines a plurality of maintenance parts to beshipped successively as a maintenance inspection progresses, when asingle machine needs said maintenance parts to be shipped successivelyduring said maintenance inspection.
 8. The centralized maintenance partmanagement system as described in claim 1, wherein said warehousefacility is an automated warehouse.
 9. The centralized maintenance partmanagement system as described in claim 3, wherein: said ordermanagement device estimates a quantity of a maintenance part neededbased on at least one of a change in a quantity of said maintenance partto be shipped from said warehouse facility, a change in a maintenanceinspection of said machines, and a change in an operating status of saidmachines; and said order management device determines said maintenancepart to be ordered and said quantity thereof.
 10. The centralizedmaintenance part management system as described in claim 2, furthercomprising an inspection period management device for storinginformation relating to periodic inspection periods for said machines,wherein when there is a new machine to be managed in one of said plants,said inspection period management device uses said information relatingto said periodic inspection periods for said machines to determine aperiodic inspection period for said machine to be newly managed that isoffset from said periodic inspection periods of said machines.
 11. Thecentralized maintenance part management system as described in claim 3,further comprising an inspection period management device for storinginformation relating to periodic inspection periods for said machines,wherein when there is a new machine to be managed in one of said plants,said inspection period management device uses said information relatingto said periodic inspection periods for said machines to determine aperiodic inspection period for said machine to be newly managed that isoffset from said periodic inspection periods of said machines.
 12. Thecentralized maintenance part management system as described in claim 4,further comprising an inspection period management device for storinginformation relating to periodic inspection periods for said machines,wherein when there is a new machine to be managed in one of said plants,said inspection period management device uses said information relatingto said periodic inspection periods for said machines to determine aperiodic inspection period for said machine to be newly managed that isoffset from said periodic inspection periods of said machines.
 13. Thecentralized maintenance part management system as described in claim 2,wherein said necessary parts management device stores and maintainsplant-by-plant inventory information indicating a quantity of saidmaintenance part stored in said plurality of plants and uses saidplant-by-plant inventory information to evaluate whether saidmaintenance part is necessary.
 14. The centralized maintenance partmanagement system as described in claim 3, wherein said necessary partsmanagement device stores and maintains plant-by-plant inventoryinformation indicating a quantity of said maintenance part stored insaid plurality of plants and uses said plant-by-plant inventoryinformation to evaluate whether said maintenance part is necessary. 15.The centralized maintenance part management system as described in claim4, wherein said necessary parts management device stores and maintainsplant-by-plant inventory information indicating a quantity of saidmaintenance part stored in said plurality of plants and uses saidplant-by-plant inventory information to evaluate whether saidmaintenance part is necessary.
 16. The centralized maintenance partmanagement system as described in claim 5, wherein said necessary partsmanagement device stores and maintains plant-by-plant inventoryinformation indicating a quantity of said maintenance part stored insaid plurality of plants and uses said plant-by-plant inventoryinformation to evaluate whether said maintenance part is necessary. 17.The centralized maintenance part management system as described in claim2, wherein, said parts shipment management device determines a pluralityof maintenance parts to be shipped successively as a maintenanceinspection progresses, when a single machine needs said maintenanceparts to be shipped successively during said maintenance inspection. 18.The centralized maintenance part management system as described in claim3, wherein, said parts shipment management device determines a pluralityof maintenance parts to be shipped successively as a maintenanceinspection progresses, when a single machine needs said maintenanceparts to be shipped successively during said maintenance inspection. 19.The centralized maintenance part management system as described in claim4, wherein, said parts shipment management device determines a pluralityof maintenance parts to be shipped successively as said maintenanceinspection progresses, when a single machine needs said maintenanceparts to be shipped successively during said maintenance inspection. 20.The centralized maintenance part management system as described in claim5, wherein, said parts shipment management device determines a pluralityof maintenance parts to be shipped successively as a maintenanceinspection progresses, when a single machine needs said maintenanceparts to be shipped successively during said maintenance inspection. 21.The centralized maintenance part management system as described in claim6, wherein, said parts shipment management device determines a pluralityof maintenance parts to be shipped successively as a maintenanceinspection progresses, when a single machine needs said maintenanceparts to be shipped successively during said maintenance inspection. 22.A method of using a centralized maintenance part management systemcomprising the steps of: storing in a warehouse facility, in acentralized manner, a maintenance part for a plurality of types ofmachines located at a plurality of plants; managing information aboutwhether said maintenance part is necessary for said machines; andspecifying a maintenance part to be shipped from said warehouse facilitybased on said management information.
 23. The method of using thecentralized maintenance part management system according to claim 22,further comprising the step of: determining a maintenance part to beordered and a quantity thereof based on inventory information of saidmaintenance part to be ordered in said warehouse facility or based onsaid management information.
 24. The method of using the centralizedmaintenance part management system according to claim 23, furthercomprising the steps of: inputting a target value for a total price ofsaid maintenance part stored in said warehouse facility; and determiningsaid quantity of said maintenance part to be ordered, said quantity ofsaid maintenance part to be ordered is reduced according to setconditions so that said total price of said maintenance part stored insaid warehouse facility approaches said target value.
 25. The method ofusing the centralized maintenance part management system according toclaim 23, further comprising the steps of: estimating a quantity of amaintenance part needed based on at least one of a change in a quantityof said maintenance part to be shipped from said warehouse facility, achange in a maintenance inspection of said machines, and a change in anoperating status of said machines; and determining said maintenance partto be ordered and said quantity thereof.
 26. The method of using thecentralized maintenance part management system according to claim 22,further comprising the steps of: storing information relating toperiodic inspection periods for said machines; and when there is a newmachine to be managed in one of said plants, using said informationrelating to said periodic inspection periods for said machines todetermine a periodic inspection period for said machine to be newlymanaged that is offset from said periodic inspection periods of saidmachines.
 27. The method of using the centralized maintenance partmanagement system according to claim 22, further comprising the stepsof: storing and maintaining plant-by-plant inventory informationindicating a quantity of said maintenance part stored in said pluralityof plants; and using said plant-by-plant inventory information toevaluate whether said maintenance part is necessary.
 28. The method ofusing the centralized maintenance part management system according toclaim 22, further comprising the step of: determining maintenance partsto be shipped successively as a maintenance inspection progresses, whena single machine needs a plurality of said maintenance parts to beshipped successively during said maintenance inspection.